U.S. patent application number 12/660373 was filed with the patent office on 2010-09-02 for polymer modified carbohydrate curable binder composition.
Invention is credited to Michael DeWayne Kelly, Haksu Lee, Barry Weinstein.
Application Number | 20100222459 12/660373 |
Document ID | / |
Family ID | 42244306 |
Filed Date | 2010-09-02 |
United States Patent
Application |
20100222459 |
Kind Code |
A1 |
Kelly; Michael DeWayne ; et
al. |
September 2, 2010 |
Polymer modified carbohydrate curable binder composition
Abstract
A curable aqueous binder composition comprising one or more
amine reactant selected from the group consisting of: a protein, a
peptide, an amino acid, an ammonium salt of a polycarboxylic acid,
an ammonium salt of a (poly)hydroxy-(poly)carboxylic acid; one or
more carbohydrate; and one or more emulsion polymer; and the use
thereof as thermosetting binders. Also described are composite
materials comprising the curable binder composition, and methods of
application.
Inventors: |
Kelly; Michael DeWayne;
(North Wales, PA) ; Lee; Haksu; (Ambler, PA)
; Weinstein; Barry; (Dresher, PA) |
Correspondence
Address: |
ROHM AND HAAS COMPANY;PATENT DEPARTMENT
100 INDEPENDENCE MALL WEST
PHILADELPHIA
PA
19106-2399
US
|
Family ID: |
42244306 |
Appl. No.: |
12/660373 |
Filed: |
February 25, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61208733 |
Feb 27, 2009 |
|
|
|
Current U.S.
Class: |
524/17 ; 524/27;
524/56; 524/58 |
Current CPC
Class: |
C08B 37/0006 20130101;
C08L 5/00 20130101 |
Class at
Publication: |
524/17 ; 524/27;
524/56; 524/58 |
International
Class: |
C08L 5/00 20060101
C08L005/00; C08L 89/00 20060101 C08L089/00 |
Claims
1. An aqueous composition comprising, as a percentage by weight of
solids: a. from 25% to 87% of one or more carbohydrate chosen from
a monosaccharide, a disaccharide, a polysaccharide, a derivative
thereof, and a combination thereof; b. at least 8% of one or more
amine reactant chosen from a protein, a peptide, an amino acid, an
ammonium salt of a polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, a derivative thereof, and a
combination thereof; and c. from 5% to 50% of one or more emulsion
polymer.
2. The aqueous composition of claim 1 wherein the monosaccharide,
disaccharide, polysaccharide, or derivative thereof comprises at
least 30% monosaccharide, disaccharide, or derivatives thereof, or
combinations thereof.
3. The aqueous composition of claim 1 wherein the monosaccharide,
disaccharide, polysaccharide, or derivative thereof comprises at
least 30% dextrose.
4. The aqueous composition of claim 1 wherein the amine reactant is
ammonium citrate.
5. The aqueous composition of claim 1 wherein the amine reactant is
an ammonium salt of poly(meth)acrylic acid.
6. The aqueous composition of claim 1 further comprising a Lewis
acid.
7. The aqueous composition of claim 1 wherein the emulsion polymer
does not comprise polymerized units of a carboxylic acid
monomer.
8. The aqueous composition of claim 1 wherein the emulsion polymer
comprises, as polymerized units, one or more multi-ethylenically
unsaturated monomer.
9. A composite material comprising: (a) a substrate material
selected from fibers, slivers, chips, particulate matter, films,
sheets, and combinations thereof; and (b) a cured binder
composition derived from an aqueous composition comprising, as a
percentage by weight of solids: i. from 25% to 87% of one or more
carbohydrate chosen from a monosaccharide, a disaccharide, a
polysaccharide, a derivative thereof, and a combination thereof;
ii. at least 8% of one or more amine reactant chosen from a
protein, a peptide, an amino acid, an ammonium salt of a
polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, a derivative thereof, and a
combination thereof; and iii. from 5% to 50% of one or more
emulsion polymer.
10. An aqueous composition comprising, as a percentage by weight of
solids: a. from 25% to 90% of one or more carbohydrate chosen from
a monosaccharide, a disaccharide, a polysaccharide, a derivative
thereof, and a combination thereof; b. at least 8% of one or more
amine reactant chosen from a protein, a peptide, an amino acid, an
ammonium salt of a polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, a derivative thereof, and a
combination thereof; and c. from 2% to 15% of one or more Lewis
acid.
Description
[0001] This application claims the benefit of priority under 35
U.S.C. 119 (e) of U.S. Provisional Patent Application Ser. No.
61/208,733 filed on Feb. 27, 2009.
[0002] The present invention relates to a carbohydrate curable
composition useful as a thermosetting binder for a variety of
applications. More particularly, the present invention relates to
aqueous binder compositions comprising one or more amine reactant
selected from the group consisting of: a protein, a peptide, an
amino acid, an ammonium salt of a polycarboxylic acid; one or more
carbohydrate; and one or more emulsion polymer; and the use thereof
as curable binders.
[0003] Due to their favorable cost/performance ratio, the
thermosetting binder resins of choice in the past have been
phenol/formaldehyde or urea/formaldehyde resins. However, curable
compositions containing little or no formaldehyde are now highly
desirable in a variety of products, due to the health and
environmental problems associated with formaldehyde. Applications
for formaldehyde resins are extensive and include fiber bonding,
composites, and fibers. These fibers may be cellulosic, polymeric
such as polyester, or mineral fibers. The mineral fibers may
consist of molten glass, slag or stonewool. Typically these fibers
are blown into a forming chamber, sprayed with a binder, and
deposited as a web on to a conveyer. The coated mineral fibers are
drawn into a curing oven and shaped into various building and
insulation products. In the case of insulation products, cured
mineral fiber binders allow the insulation to be compressed, but
have rigidity that allows the compressed insulation to recover
substantially to its original shape once compressive forces are
removed. This allows, for example, the insulation to be shipped in
a rolled, compressed state and unrolled before installation to
release the compression, and allow a fluffy, heat-insulating mat to
be installed.
[0004] Rigid binders may find use, for example, in mineral wool
applications such as fiberglass and stonewool insulation, and
acoustic panels. For other applications, such as where rigid
binders are unsuitable, for example, in thin fiberglass or
polyester mats that are to be used in roofing, the mat is held
together with a binder that allows the mat to flex substantially
after the binder is cured, to allow the mat to be processed further
(e.g., to convert mat into roofing material), and allow the end
product containing the mat to flex well in use. For example, in
roofing mat, the end roofing product may be impregnated or layered
with asphaltic materials, and the resultant roofing product retains
flexibility to allow it to conform to the roof (e.g., bend over
peaks and into valleys), and to allow the roofing material to
expand and contract with temperature fluctuations, without the mat
itself fracturing because it is too brittle and lacks flexibility.
Other applications where curable, formaldehyde-free binders that
are "flexible" are useful in this regard include paper,
cellulosics, polyester, glass mat, and glass veil. Such substrates
are used in a variety of applications, including flooring
underlayments, filtration media, and building products.
[0005] Existing commercial aqueous formaldehyde-free binder
compositions most commonly comprise a soluble polycarboxylic acid
polymer and a polyol that esterify and form a thermoset when heat
cured. However, given that soluble polymers have a relatively high
acid monomer content, binders and composite materials derived from
these binder compositions tend to be stiff and unsuitable for
flexible substrates. Moreover, these binders are known to be
derived primarily from petroleum feed stocks which are dwindling
and experiencing wide price fluctuations. Formaldehyde-free binders
derived from alternative feed-stocks are desired.
[0006] One alternative to petroleum is described in International
Patent Publication No. WO 2007/014236, which discloses binders to
produce or promote cohesion in non or loosely assembled matter,
which binder compositions comprise an amine component, which is
either a protein, a peptide, an amino acid, or an ammonium salt of
a polycarboxylic reactant in combination with a reducing sugar or
non-carbohydrate carbonyl component, and which binder is thought to
cure by way of a Maillard reaction. However, these binder
compositions are also stiff and unsuitable for flexible substrates,
and, additionally, fail to develop sufficient strength for most
applications.
[0007] There remains a need for an inexpensive, formaldehyde-free,
thermoset binder from renewable materials that provides both
flexibility and strength to the end product. To solve the problem
of providing renewable source thermosetting binders with both
strength and flexibility, the present inventors have sought to
provide a formaldehyde free binder of the present invention.
STATEMENT OF THE INVENTION
[0008] The present invention provides aqueous compositions which
may function as binders comprising one or more amine component
chosen from a protein, a peptide, an amino acid, an ammonium salt
of a polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, and mixtures thereof; in
combination with a carbohydrate or a non-carbohydrate carbonyl
component; and at least one emulsion polymer. Preferably, the
emulsion polymer has a glass transition temperature, Tg, no greater
than 70.degree. C. Preferably, the carbohydrate is a monosaccharide
or disaccharide. In a preferred embodiment, the aqueous binder
composition additionally comprises a Lewis acid catalyst.
[0009] Thus, this invention is an aqueous formaldehyde-free binder
composition, which, upon curing on a suitable substrate material,
provides a binder and a composite material comprising the cured
binder, having both flexibility and strength. This invention
provides aqueous compositions which may function as aqueous binder
compositions.
[0010] The present invention provides an aqueous composition
comprising, as a percentage by weight of solids: a) from 25% to 87%
of one or more carbohydrate chosen from a monosaccharide, a
disaccharide, a polysaccharide, a derivative thereof, and a
combination thereof; b) at least 8% of one or more amine reactant
chosen from a protein, a peptide, an amino acid, an ammonium salt
of a polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, a derivative thereof, and a
combination thereof; and c) from 5% to 50% of one or more emulsion
polymer.
[0011] In one embodiment, the monosaccharide, disaccharide,
polysaccharide, or derivative thereof comprises at least 30%
monosaccharide, disaccharide, or derivative thereof, or combination
thereof. In another embodiment, the monosaccharide, disaccharide,
polysaccharide, or derivative thereof comprises at least 30%
dextrose.
[0012] In yet another embodiment, the monosaccharide, disaccharide,
polysaccharide, or derivative thereof comprises corn syrup
comprising at least 30% dextrose.
[0013] In a further embodiment, the amine reactant is ammonium
citrate.
[0014] In a different embodiment, the amine reactant is an ammonium
salt of poly(meth)acrylic acid.
[0015] In still another embodiment, the aqueous composition further
comprises a Lewis acid.
[0016] In an alternative embodiment, the emulsion polymer does not
comprise polymerized units of a carboxylic acid monomer.
[0017] In another alternative embodiment, the emulsion polymer
comprises, as polymerized units, one or more multi-ethylenically
unsaturated monomer.
[0018] In addition, the present invention provides methods of
treating substrates with the aqueous binder compositions,
optionally followed by heat curing. Although the compositions may
find use as binders even without any curing, or after minimal cure,
preferably, the compositions are heated to provide a cured
binder.
[0019] For each composition described herein, there exists an
accompanying embodiment in which the aqueous composition is a
binder composition and in which the composition is present in a
composite material or product. As defined herein, the term
"composite material" refers to materials comprising: (a) a
substrate material selected from fibers, slivers, chips,
particulate matter, films, sheets, and combinations thereof; and
(b) the binder composition of the described embodiment.
[0020] Thus, in another aspect of the invention, there is provided
a composite material comprising: (a) a substrate material selected
from fibers, slivers, chips, particulate matter, films, sheets, and
combinations thereof; and (b) a cured binder composition derived
from an aqueous composition comprising, as a percentage by weight
of solids: (i) from 25% to 87% of one or more carbohydrate selected
from the group consisting of: a monosaccharide, a disaccharide, a
polysaccharide, a derivative thereof, and a combination thereof;
(ii) at least 8% of one or more amine reactant selected from the
group consisting of: a protein, a peptide, an amino acid, an
ammonium salt of a polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, a derivative thereof, and a
combination thereof; and (iii) from 5% to 50% of one or more
emulsion polymer.
[0021] In a further aspect of the invention, there is provided an
aqueous composition comprising, as a percentage by weight of
solids: (a) from 25% to 90% of one or more carbohydrate selected
from the group consisting of: a monosaccharide, a disaccharide, a
polysaccharide, a derivative thereof, and a combination thereof;
(b) at least 8% of one or more amine reactant selected from the
group consisting of: a protein, a peptide, an amino acid, an
ammonium salt of a polycarboxylic acid, an ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, a derivative thereof, and a
combination thereof; and (c) from 2% to 15% of one or more Lewis
acid.
[0022] As used herein, the phrase "alkyl" means any aliphatic alkyl
group having one or more carbon atoms, the alkyl group including
n-alkyl, s-alkyl, i-alkyl, t-alkyl groups or cyclic aliphatics
containing one or more 5, 6 or seven member ring structures. As
used herein, the term "amine reactant" refers to one or more
compounds possessing an amino group, including proteins, peptides
and amino acids, as well as ammonium salts of a polycarboxylic
acid, or ammonium salts of a (poly)hydroxy-(poly)carboxylic acid,
which species may be monomeric or polymeric.
[0023] As used herein, the term "ammonium" includes, but is not
limited to, NH.sub.4, .sup.+NH.sub.3R.sup.1,
.sup.+NH.sub.2R.sup.1R.sup.2, where R.sup.1 and R.sup.2 are each
independently selected, and where R.sup.1 and R.sup.2 are selected
from alkyl, cycloalkyl, alkenyl, cycloalkenyl, heterocyclyl, aryl,
and heteroaryl. That is, the term "ammonium" includes "alkyl
ammonium".
[0024] As used herein, the term "polycarboxylic acid" may refer, in
the alternative, to a dicarboxylic acid, tricarboxylic acid,
tetracarboxylic acid, pentacarboxylic acid, and like monomeric
polycarboxylic acids, and anhydrides, and combinations thereof, as
well as polymeric polycarboxylic acids, and anhydrides, and
combinations thereof. The polycarboxylic acid may be substituted
with other chemical functional groups.
[0025] Unless otherwise indicated, any term containing parentheses
refers, alternatively, to the whole term as if no parentheses were
present and the term without that contained in the parentheses, and
combinations of each alternative. Thus, as used herein, the term
"(meth)acrylate" means acrylate, methacrylate, and mixtures thereof
and the term "(meth)acrylic" used herein means acrylic,
methacrylic, and mixtures thereof.
[0026] As used herein, the term "(poly)hydroxy-(poly)carboxylic
acid" encompasses, in the alternative, the term
"polyhydroxy-polycarboxylic acid", or "monohydroxy-polycarboxylic
acid", or "polyhydroxy-monocarboxylic acid", or
"monohydroxy-monocarboxylic acid".
[0027] As used herein, the term "(poly)saccharide" encompasses, in
the alternative, polysaccharide, or the generic term "saccharide"
(which latter, following its use in the art, may include a
polysaccharide, a monosaccharide, or a disaccharide), or mixtures
thereof.
[0028] As used herein, the term "reducing sugar" refers to one or
more sugars that contain aldehyde groups, or that can isomerize,
i.e. tautomerize, to contain aldehyde groups, which groups are
reactive with an amino group under Maillard reaction conditions and
which groups may be oxidized to afford carboxylic acids.
[0029] As used herein, the phrase "aqueous" or "aqueous solvent"
includes water and mixtures composed substantially of water and
water-miscible solvents.
[0030] As used herein, "wt %" or "wt. percent" means weight percent
based on solids.
[0031] As used herein, the phrase "based on the total weight of
binder solids" or "weight percent of the total solids in the
binder" refers to weight amounts of any given ingredient in
comparison to the total weight amount of all the non-water
ingredients in the binder (e.g., carbohydrate(s), amine or ammonium
compound(s), Lewis acid salt(s), emulsion copolymer(s), and the
like). Binder compositions of this invention can be aqueous or dry
(with water optionally added prior to application to a
substrate).
[0032] As used herein, the term "polymer" includes the term
"copolymer", and, unless otherwise indicated, the term "copolymer"
refers to polymers made from any two or more different monomers,
including, for example, terpolymers, pentapolymers, homopolymers
functionalized after polymerization so that two or more different
functional groups are present in the product copolymer, block
copolymers, segmented copolymers, graft copolymers, and any mixture
or combination thereof. (Co)polymer means homopolymer or
copolymer.
[0033] As used herein, the phrase "emulsion polymer" refers to a
(co)polymer that has been prepared by emulsion polymerization.
[0034] As used herein, the phrase "formaldehyde-free composition"
refers to compositions substantially free from added formaldehyde,
and which do not liberate substantial formaldehyde as a result of
drying and/or curing. Preferably, the binder or material that
incorporates the binder liberates less than 10 ppm of formaldehyde,
more preferably less than 1 ppm of formaldehyde, as a result of
drying and/or curing the binder (10 pppm or 1 ppm based on the
weight of sample being measured for formaldehyde release).
[0035] As used herein, the phrases "(C.sub.3-C.sub.12)-" or
"(C.sub.3-C.sub.6)-" and the like refer to organic compounds or
structural portions of organic compounds containing 3 to 12 carbon
atoms and 3 to 6 carbon atoms, respectively.
[0036] The singular forms "a," "an," and "the" include plural
referents unless the context clearly dictates otherwise. Unless
defined otherwise, technical and scientific terms used herein have
the same meaning as is commonly understood by one skilled in the
art. The endpoints of all ranges directed to the same component or
property are inclusive of the endpoint and independently
combinable.
[0037] As used herein, unless otherwise indicated, the phrase
"glass transition temperature" or "Tg" refers to a measured Tg,
determined by differential scanning calorimetry (DSC) using a
heating rate of 10.degree. C./minute, taking the mid-point in the
heat flow versus temperature transition as the Tg value.
[0038] Unless otherwise indicated, conditions of temperature and
pressure are room temperature and standard pressure, also referred
to as "ambient conditions". The compositions may be dried under
conditions other than ambient conditions.
[0039] As used herein, unless otherwise indicated, the phrase
"molecular weight" with respect to a polymer refers to the weight
average molecular weight of a polymer as measured by gel permeation
chromatography (GPC). Gel permeation chromatography, otherwise
known as size exclusion chromatography, actually separates the
members of a distribution of polymer chains according to their
hydrodynamic size in solution rather than their molar mass. The
system is then calibrated with standards of known molecular weight
and composition to correlate elution time with molecular weight.
The techniques of GPC are discussed in detail in Modern Size
Exclusion Chromatography, W. W. Yau, J. J Kirkland, D. D. Bly;
Wiley-Interscience, 1979, and in A Guide to Materials
Characterization and Chemical Analysis, J. P. Sibilia; VCH, 1988,
p. 81-84.
[0040] The molecular weight information for a low molecular weight
sample (e.g., 10,000) may be determined more accurately by
techniques such as mass spectrometry or light scattering techniques
as is known in the art. Herein, lower molecular weights, such as
polysaccharides, are determined by gel permeation chromatography
with laser light scattering.
[0041] The inventive aqueous binder composition comprises one or
more amine component, which is either a protein, a peptide, an
amino acid, or an ammonium salt of a polycarboxylic reactant in
combination with a carbohydrate or a non-carbohydrate carbonyl
component, and further comprising at least one emulsion polymer.
The reaction between the amine component and the carbohydrate or
non-carbohydrate carbonyl component may proceed in a manner
analogous to that of a Maillard reaction, and may produce
melanoidins. Melanoidins are high molecular weight, furan ring and
nitrogen-containing polymers that vary in structure depending on
the reactants and conditions of preparation. The cured binders of
the invention may therefore comprise such melanoidin species. In
the alternative, melanoidin species may be prepared separately and
added to the aqueous binder compositions. Likewise, similar
Maillard reactions may be performed separately, and any or all of
the reaction products thereof may be added to the aqueous binder
compositions.
[0042] The aqueous binder composition of the present invention
comprises at least one carbohydrate or a non-carbohydrate carbonyl
component. The term carbohydrate refers to polyhydroxylated
compounds many of which contain aldehydic or ketonic groups or
yield such groups on hydrolysis. Simple carbohydrates are referred
to as sugars or saccharides. Sugars refer to monosaccharides,
disaccharides, or polysaccharides, depending on the number of sugar
units linked together. Monosaccharides usually consist of five or
six carbon atoms and are referred to as pentoses and hexoses,
repectively. If the monosaccharide contains an aldehyde it is
referred to as an aldose; if it contains a ketone, it is referred
to as a ketose. The aqueous binder composition may comprise one or
more monosaccharide, or disaccharide, or polysaccharide, or
degradation product thereof. The carbohydrate component may be a
monosaccharide in its aldose or ketose form, including a triose, a
tetrose, a pentose, a hexose, or a heptose; or a disaccharide; or a
polysaccharide; or combinations thereof. Glyceraldehyde and
dihydroxyacetone are considered to be aldotriose and ketotriose
sugars, respectively. Examples of aldotetrose sugars include
erythrose and threose; and ketotetrose sugars include erythrulose.
Aldopentose sugars include ribose, arabinose, xylose, and lyxose;
and ketopentose sugars include ribulose, arabulose, xylulose, and
lyxulose. Examples of aldohexose sugars include glucose (for
example, dextrose), mannose, galactose, allose, altrose, talose,
gulose, and idose; and ketohexose sugars include fructose, psicose,
sorbose, and tagatose. Ketoheptose sugars include sedoheptulose.
Other natural or synthetic stereoisomers or optical isomers of such
carbohydrates may also be useful as the carbohydrate component of
the aqueous binder composition. Similarly, polysaccharides
(including disaccharides) may find use in the aqueous binder
compositions, for example, sucrose, lactose, maltose, starch, and
cellulose. A number of powdered or granulated sugars or sugar
syrups, including corn syrup, high fructose corn syrup, and the
like, may act as sources of the carbohydrate component of the
aqueous binder composition.
[0043] The carbohydrate component or non-carbohydrate carbonyl
component of the aqueous binder composition optionally may be
substituted, for example with hydroxy, halo, alkyl, alkoxy, or
other substituent groups.
[0044] Higher molecular weight polysaccharides that may be useful
in the binder of this invention include those selected from the
group consisting of starch, cellulose, gums such as guar and
xanthan, alginates, chitosan, pectin, gellan and modifications or
derivatives thereof which are provided by etherification,
esterification, acid hydrolysis, dextrinization, oxidation or
enzyme treatment. Such polysaccharides can be derived from natural
products, including plant, animal and microbial sources.
Polysaccharide starches include maize or corn, waxy maize, high
amylose maize, potato, tapioca and wheat starches. Other starches
include varieties of rice, waxy rice, pea, sago, oat, barley, rye,
amaranth, sweet potato, and hybrid starches available from
conventional plant breeding, e.g., hybrid high amylose starches
having amylose content of 40% or more, such as high amylose corn
starch. Genetically engineered starches, such as high amylose
potato and potato amylopectin starches, may also be useful.
[0045] The polysaccharides may be modified or derivatized, such as
by etherification, esterification, acid hydrolysis, dextrinization,
oxidation or enzyme treatment (e.g., with alpha-amylase,
beta-amylase, pullulanase, isoamylase, or glucoamylase), or
bio-engineered.
[0046] The polysaccharide used in this inventive binder composition
may have a weight average molecular weight of greater than 10,000,
or greater than 100,000 (e.g. as high as 1,000,000 or even as high
as 10,000,000). However, lower molecular weight (poly)saccharides
are preferred; the (poly)saccharide preferably has a weight average
molecular weight of less than 10,000, or, even, less than 1,000. In
one embodiment, the (poly)saccharide preferably has a molecular
weight of less than 500. Weight average molecular weight of the
(poly)saccharide is measured using gel permeation chromatography
with laser light scattering.
[0047] Thus, most preferably, the (poly)saccharide is a
monosaccharide or disaccharide. In one embodiment, the
(poly)saccharide is a reducing sugar. Dextrose has been found to be
particularly suitable. In one exemplary embodiment, a high dextrose
content syrup (greater than 30% dextrose) is used as the
carbohydrate component. In such syrups, the higher the dextrose
content, the better.; syrups with 97%, or greater, dextrose content
are commercially available, for example ADM 97/71 corn syrup, from
Archer Daniels Midland Company (Decatur, Ill., USA).
[0048] Additionally, non-carbohydrate carbonyl compounds may
undergo similar reaction types with the amine component in
producing melanoidins. Thus, alternatively, the aqueous binder
composition may comprise a non-carbohydrate carbonyl component.
Examples of non-carbohydrate carbonyl reactants include various
aldehydes, such as pyruvaldehyde and furfural, as well as compounds
such as ascorbic acid and quinone, which may be capable of
producing melanoidin compounds by reaction with the amine reactant.
The carbohydrate or a non-carbohydrate carbonyl component of the
aqueous binder composition may be one or more of those described
herein, or a combination thereof.
[0049] Preferably, the carbohydrate or non-carbohydrate carbonyl
component should be sufficiently non-volatile to maximize its
ability to remain in the binder composition during the heating or
curing thereof.
[0050] The carbohydrate or non-carbohydrate carbonyl component may
comprise from 25%, or from 50%, or from 60%, up to 87%, or up to
85%, or up to 70%, by weight of solids as a percent of the total
solids in the binder; preferably the carbohydrate or
non-carbohydrate carbonyl component comprises from 70%, or from
75%, or from 80%, up to 90%, or up to 85%, or up to 80% by weight
of solids as a percent of the total solids in the binder; and most
preferably from 70-80%, or 75-85%.
[0051] The aqueous binder composition comprises at least one amine
reactant. The amine reactant may be one or more protein, or
peptide, or amino acid, or, urea, or polyacrylamide, or ammonium
salt of a polycarboxylic acid, or ammonium salt of a
(poly)hydroxy-(poly)carboxylic acid, or combination thereof. The
polycarboxylic acid or (poly)hydroxy-(poly)carboxylic acid species
may be monomeric or polymeric. Moreover, such species may be
substituted with other chemical functional groups. For example, the
(poly)hydroxy-(poly)carboxylic acid species may be, for example, an
unsaturated aliphatic (poly)hydroxy-(poly)carboxylic acid, a
saturated aliphatic (poly)hydroxy-(poly)carboxylic acid, an
aromatic (poly)hydroxy-(poly)carboxylic acid, an unsaturated cyclic
(poly)hydroxy-(poly)carboxylic acid, a saturated cyclic
(poly)hydroxy-(poly)carboxylic acid, anhydrides thereof, or mixture
thereof. Further, such (poly)hydroxy-(poly)carboxylic acid species
may be optionally substituted, such as with halo, alkyl, alkoxy,
and the like. The ammonium salt of a polycarboxylic acid, or
ammonium salt of a (poly)hydroxy-(poly)carboxylic acid may be
mono-basic, or dibasic, or polybasic depending on the acid.
Moreover, the molar equivalents of ammonium ion may or may not be
equal to the molar equivalents of acid salt groups present on the
polycarboxylic acid.
[0052] The term polycarboxylic acid may refer, in the alternative,
to a dicarboxylic acid, tricarboxylic acid, tetracarboxylic acid,
pentacarboxylic acid, and like monomeric polycarboxylic acids, and
anhydrides, and combinations thereof, as well as polymeric
polycarboxylic acids, and anhydrides, and combinations thereof.
[0053] Examples of monomeric polycarboxylic acid include itaconic
acid, citric acid, lactic acid, aconitic acid, adipic acid, azelaic
acid, maleic acid, malic acid, succinic acid, and the like, and
anhydrides, and combinations thereof.
[0054] Examples of polymeric polycarboxylic acid include water
soluble polyacrylic acid, poly(methacrylic acid), and poly(maleic
acid). Alternatively, the polymeric polycarboxylic acid may be
prepared from unsaturated anhydrides, or mixtures of unsaturated
anhydrides, such as maleic anhydride, (meth)acrylic anhydride, and
the like. Alternatively, the polymeric polycarboxylic acid may
comprise a copolymer of one or more of the aforementioned
unsaturated carboxylic acids or anhydrides and one or more vinyl
compounds including, but not necessarily limited to styrene,
alpha-methylstyrene, vinyl actate, vinyl alkyl ethers,
(meth)acrylonitrile, and esters of (meth)acrylic acid, such as
methyl (meth)acrylate, butyl (meth)acrylate and ethylhexyl
(meth)acrylate. Water soluble polyacids have previously found
utility as binders, for example with polyol components, and
optionally with catalysts. Aquaset.TM.-529 (available from Rohm and
Haas Company, Philadelphia, PS, USA) is one such example,
comprising a polyacrylic acid, glycerol and sodium hypophosphite as
a catalyst. Similarly, non-carbohydrate polyols (compounds
comprising two or more hydroxyl groups) may be included in the
compositions of the current invention, for example, glycerol,
diethanolamine, triethanolamine, beta-hydroxyalkylamides, and the
like, as is known in the art. Preferably, any non-carbohydrate
polyol component should be sufficiently non-volatile to maximize
its ability to remain in the binder composition during the heating
or curing thereof. Hydrolyzed or partially hydrolyzed polyvinyl
acetate polymers may serve as the non-carbohydrate polyol.
Likewise, phosphorus containing accelerators, such as sodium
hypophosphite, potassium polyphosphate, and the like, as is known
in the art, may be included in the compositions of the current
invention.
[0055] Mixed ammonium salts of the (poly)acid are also
contemplated, for example in the event a polymeric polycarboxylic
acid is partially neutralized with sodium hydroxide, and then
further neutralized with ammonium hydroxide. As discussed earlier,
the term "ammonium" includes "alkyl ammonium". Preferably, the
aqueous binder composition is at an alkaline pH (a pH of 7 or
higher), which minimizes corrosion of any mixing or storage or
processing equipment. In one embodiment, the pH of the aqueous
binder composition is less than or equal to 10.
[0056] Preferably, the polycarboxylic acid ammonium salt or amine
component should be sufficiently non-volatile to maximize its
ability to remain in the binder composition during the heating or
curing thereof.
[0057] Preferably, the amine reactant is selected from an ammonium
salt of a monomeric or polymeric polycarboxylic acid, and an
ammonium salt of a (poly)hydroxy-(poly)carboxylic acid. Preferred
amine reactants include ammonium salts of poly(meth)acrylic acid or
ammonium salts of citric acid.
[0058] The ammonium salt may be present at a level of 8-75 weight
percent based on solids as a percentage of the total solids in the
binder. Preferably, the ammonium salt is present at a level of from
10%, or from 15%, up to a level of 50%, or up to 30%; and, most
preferably, is at a level of from 10% up to 15% or up to 20% based
on solids as a percentage of the total solids in the binder.
[0059] As indicated earlier, for each embodiment for which the
binder composition comprises an amine reactant component and a
carbohydrate component, there exists also an alternative embodiment
for which the carbohydrate component is replaced with, or combined
with, a non-carbohydrate carbonyl reactant.
[0060] Optionally, the aqueous binder composition of the invention
may comprise a Lewis acid. Lewis acids useful in the present
invention include, but are not limited to, titanates and zirconates
such as organic titanates and zirconates sold by DuPont under the
Trade name Tyzor, for example, but not limited to, water soluble
Tyzors such as Tyzor.TM. LA, Tyzor.TM. 131, Tyzor.TM. 217, and
Tyzor.TM. 218; dibutyltindilaurate, other organo-tin salts,
inorganic tin salts such as tin(IV)chloride and corresponding
sulfates or nitrates; Al.sub.2(SO.sub.4).sub.3.xH.sub.2O,
MgCl.sub.2.6H.sub.2O, AlK(SO.sub.4).sub.2.10H.sub.2O,
Al.sub.2Zn(SO.sub.4).sub.4, and Lewis acids having the formula
MX.sub.n wherein M is a metal, X is a halogen atom or an inorganic
radical or anion (including polyatomic radicals or anions, such as
sulfate, nitrate, and the like), and n is an integer of from 1 to
5, such as BX.sub.3, AlX.sub.3, FeX.sub.3, GaX.sub.3, SbX.sub.3,
SnX.sub.4, AsX.sub.5, ZnX.sub.2, and HgX.sub.2. A combination of
Lewis acid catalysts may also be used. Preferably, the Lewis acid
is water soluble (having a solubility in water of greater than 1
gram per liter). Preferably, the Lewis acid catalyst is selected
from the group consisting of: sulfates, nitrates, halides,
citrates, lactates, and gluconates of zinc, aluminum, zirconium,
iron, copper, magnesium, tin, titanium and boron; and their mixed
metal salts; organo-tin compounds or salts; and titanates or
zirconates of alcohols or (poly)carboxylic acids.
[0061] The Lewis acid may be present at a level of 2-15 weight
percent based on solids as a percentage of the total solids in the
binder. Preferably, the Lewis acid is present at a level of from
3%, or from 5%, up to a level of 15%, or up to 12%, or up to 6%;
and, most preferably, is at a level of from 5% up to 10% based on
solids as a percentage of the total solids in the binder.
[0062] The aqueous binder composition additionally comprises an
aqueous emulsion copolymer, which latter provides greater
flexibility and elasticity to both the binder and the cured
thermoset product.
[0063] Ethylenically unsaturated co-monomers useful in the emulsion
copolymer include (meth)acrylic ester monomers such as methyl
(meth)acrylate, ethyl (meth)acrylate, butyl (meth)acrylate,
2-ethylhexyl (meth)acrylate, decyl (meth)acrylate, isodecyl
(meth)acrylate, hydroxyethyl (meth)acrylate, and hydroxypropyl
(meth)acrylate; (meth)acrylamide or substituted (meth)acrylamides;
styrene or substituted styrenes; butadiene; vinyl acetate or other
vinyl esters; acrylonitrile or methacrylonitrile; and the like.
Styrene-acrylic latexes or all-acrylic latexes have been found to
be well-suited to the performance requirements of the targeted end
products.
[0064] In one embodiment, the latex emulsion copolymer of this
invention comprises one or more copolymerized multi-ethylenically
unsaturated monomers such as, for example, allyl methacrylate
(ALMA), allyl acrylate, diallyl phthalate, 1,4-butylene glycol
dimethacrylate, 1,2-ethylene glycol dimethacrylate, 1,6-hexanediol
diacrylate, butadiene, trimethylolpropane triacrylate (TMPTA) and
divinyl benzene. Of these, ALMA, divinylbenzene (DVB), diallyl
phthalate, 1,4-butylene glycol dimethacrylate, and 1,6-hexanediol
diacrylate are preferred. ALMA is the most preferred. The
multi-ethylenically unsaturated monomer can be effectively employed
at levels as low as 0.1%, by weight based on the weight of the
copolymer, preferably from 0.1 to 10%, or 0.1 to 5%, more
preferably from 0.1 to 4%, or 0.2 to 4%, and most preferably from
0.1 to 2%, or 0.2 to 2%, or 0.25 to 2%, or 1.0 to 2%, by weight
based on the weight of the copolymer.
[0065] The emulsion copolymer used in the binder of this embodiment
of the invention may include, as copolymerized units, a carboxy
monomer bearing a carboxylic acid group, anhydride group, or salt
thereof or hydroxyl-group, such as (meth)acrylic acid and
hydroxyethyl(meth)acrylate. For example, the emulsion copolymer may
be a high acid polymer, a low acid polymer, or it may not comprise
any acid monomer, depending on the desired property balance of the
resulting binder. For example, a high acid polymer may comprise
from 5% to 40%, or 5% to 30%, or 10% to 20%, by weight based on the
weight of the emulsion copolymer solids, of the carboxy monomer
bearing a carboxylic acid group, anhydride group, or salt thereof,
such as (meth)acrylic acid. Preferably, the emulsion polymer is an
insoluble polymer dispersion in water. A low acid polymer may
comprise from 1% to 5%, or 1% to 3%, by weight based on the weight
of the emulsion copolymer solids, of the carboxy monomer bearing a
carboxylic acid group, anhydride group, or salt thereof.
Ethylenically unsaturated carboxylic acid monomers include, for
example, methacrylic acid, acrylic acid, crotonic acid, fumaric
acid, maleic acid, 2-methyl maleic acid, itaconic acid, 2-methyl
itaconic acid, a,b-methylene glutaric acid, monoalkyl maleates, and
monoalkyl fumarates; ethylenically unsaturated anhydrides such as,
for example, maleic anhydride, itaconic anhydride, acrylic
anhydride, and methacrylic anhydride; and salts thereof. If a
carboxylic acid monomer is present, acrylic acid is preferred.
Preferably, the emulsion copolymer does not comprise a carboxy
monomer bearing a carboxylic acid group, anhydride group, or salt
thereof.
[0066] Chain transfer agents such as mercaptans, polymercaptans,
and halogen compounds can be used in the polymerization mixture in
order to moderate the molecular weight of the emulsion copolymer.
Generally, from 0% to 10% by weight, based on the weight of the
emulsion copolymer, of C.sub.4-C.sub.20 alkyl mercaptans,
mercaptopropionic acid, or esters of mercaptopropionic acid, can be
used. Preferably, the emulsion copolymer used in this invention has
a Tg of between 0-35.degree. C., preferably 5-20.degree. C., for
non-treated substrates having an inherent elongation of greater
than 5%, such as spunbond polyester; and between 35-70.degree. C.
for non-treated substrates having an inherent elongation of less
than 5%, such as glass mat, as measured by differential scanning
calorimetry per ASTM 3418/82, midpoint temperature; cell
calibration using an indium reference for temperature and
enthalpy.
[0067] The emulsion copolymer used in this invention has weight
average molecular weight of from 5,000 to 2,000,000, preferably
from 20,000 to 1,000,000. For applications requiring high
performance at elevated temperatures, the emulsion copolymer most
preferably has a weight average molecular weight of 100,000 to
1,000,000, however, for some room temperature applications, the
molecular weight is most preferably from 30,000 to 600,000.
Preferably, the emulsion polymer has a glass transition
temperature, Tg, no greater than 70.degree. C., more preferably, no
greater than 50.degree. C., and most preferably, no greater than
20.degree. C.
[0068] The emulsion polymer may be present in the composition in an
amount of from 5%, or from 10%, up to 80%, or up to 50%, or up to
30% by weight of solids as a percent of the total weight of solids
in the binder; preferably from 5% to 25%, or, most preferably, from
5% to 20%.
[0069] In a preferred embodiment suitable for binders that require
some flexibility, the aqueous binder composition comprises
approximately 70-80% by weight, based on the total weight of binder
solids, of a saccharide such as dextrose, approximately 10-20% of
an ammonium salt of a monomeric polycarboxylic acid, such as
ammonium citrate, and approximately 5-15% by weight, based on the
total weight of binder solids, of an acrylic or styrene acrylic
emulsion polymer.
[0070] In a particularly preferred embodiment, the composition
further comprises a Lewis acid catalyst, such as zinc sulfate, in
an amount of approximately 5-10 wt. %, based on the total weight of
solids of the other components of the composition.
[0071] The binder of this invention can contain, in addition,
conventional treatment components such as, for example,
emulsifiers; pigments; fillers or extenders, such as clays and
talcs; anti-migration aids; curing agents; coalescents;
surfactants, particularly nonionic surfactants; spreading agents;
mineral oil dust suppressing agents; biocides; plasticizers;
organosilanes; anti-foaming agents such as dimethicones and
emulsified poly(dimethacones), silicone oils and ethoxylated
nonionics; corrosion inhibitors, such as thioureas, oxalates, and
chromates; colorants; antistatic agents; lubricants; waxes;
anti-oxidants; coupling agents such as silanes, particularly
Silquest.TM. A-187 (manufactured by GE Silicones-OSi Specialties,
located in Wilton Conn.); other amino silanes; epoxy silanes, vinyl
silanes and hydrophobic silanes. Other additives may include
polymers not of the present invention; and waterproofing agents
such as silicones and emulsion polymers, particularly hydrophobic
emulsion polymers containing, as copolymerized units, greater than
30% by weight, based on the weight of the emulsion polymer solids,
ethylenically-unsaturated acrylic monomer containing a C5 or
greater alkyl group.
[0072] Additionally, this invention includes methods for treating
substrates comprising: Forming the wet, uncured web of fibers, and
preferably transferred to a moving screen running through a binder
application station where the aqueous binder of the invention is
applied to the mat. The binder can be applied to the structure by
any suitable means including, for example, air or airless spraying,
padding, saturating, roll coating, curtain coating, beater
deposition, coagulation or dip and squeeze application, and the
resultant saturated wet bindered web laying on a supporting wire or
screen is run over one or more vacuum boxes to remove enough binder
to achieve the desired binder content in the mat. The binder level
in the inventive mats can range from 5 or from 10 to 35 wt. percent
of the finished dry mat, preferably 12 to 30 wt. percent. The
binder composition is curable by the application of heat, i.e., the
binder composition is a thermosetting composition.
[0073] The binders of this invention are useful to bind non-woven
webs, among other things. "Non-woven web(s)" refers to any article
or sheet-like form made from natural and/or synthetic fibers
wherein the fibers are aligned in a random or semi-random order
(i.e., not deliberately ordered). One skilled in the art
understands that formation of some order occurs during the web
forming process (primarily in the machine direction); however, this
is completely different from the ordering obtained from traditional
weaving or knitting processes. Suitable fibers for use in forming
the web include, but are not limited to, fiberglass, cellulose,
modified cellulose (cellulose acetate), cotton, polyesters, rayon,
polyacrylonitrile (PAN), polylactic acid (PLA), polycaprolactone
(PCL), polyolefins and bi-component fiber comprising two or more
fiber-forming polymers such as polypropylene and polyethylene
terephthalate and the like. Included in the definition of non-woven
webs suitable for use with this invention are porous films prepared
by the action of chemical or mechanical processing (e.g., apertured
films). Also included as useful for the purpose of this invention
are paper and paper products. The present invention will find
utility with any weight of non-woven web and will depend greatly on
the requirements of the particular application. Manufacturing
processes for making non-woven webs are well known in the art.
These include, for example, wet-laid, air-laid (dry laid),
spunbond, spunlace, meltblown and needle punch. Particularly
suitable webs will have a base weight (i.e., the weight of the web
before any coating or treatments are applied) of less than 100
grams per square meter (gsm). In another aspect the webs will have
a base weight of less than 20 gsm.
[0074] The composition components need not all be pre-mixed prior
to application of the binder to the substrate. For example, one or
more components may be applied to a non-woven substrate, followed
by application of the other binder components of this invention
either in aqueous or dried form. After application, the binder can
be cured by heating the coated non-woven to a sufficient
temperature where it cures on the substrate.
[0075] Preferably, the binder compositions are formaldehyde-free.
To minimize the formaldehyde content of the aqueous composition, it
is preferred, when preparing a polymer-containing formaldehyde-free
curable composition, to use polymerization adjuncts and additives
such as, for example, initiators, reducing agents, chain transfer
agents, curing agents, biocides, surfactants, emulsifiers, coupling
agents, anti-foaming agents, dust suppressing agents, fillers and
the like, which are themselves free from formaldehyde, do not
generate formaldehyde during the polymerization process, and do not
generate or emit formaldehyde during the treatment of
heat-resistant nonwovens.
[0076] In drying (if applied in aqueous form) and curing the
curable compositions, the duration, and temperature of heating,
will affect the rate of drying, ease of processing or handling, and
property development of the treated substrate. Suitable heat
treatment at 100.degree. C. or more, and up to 400.degree. C., may
be maintained for from 3 seconds to 15 minutes. Preferably, heat
treatment temperatures range 150.degree. C. or higher; such
preferred heat treatment temperatures may range up to 225.degree.
C., or, more preferably, up to 200.degree. C. or, up to 150.degree.
C. Where the substrate contains wood, temperatures of 100.degree.
C. to 220.degree. C., are preferred.
[0077] Drying and curing can be done in two or more distinct steps,
if desired. For example, the curable composition can be first
heated at temperatures and for times sufficient to at least
partially dry, but not to fully cure the composition, followed by
heating for a second time, at higher temperatures and/or for longer
periods of time, to effect curing. Such procedures, referred to as
"B-staging," can be used to provide binder-treated nonwovens, for
example, in roll form, which can be cured later, with or without
forming or molding into a particular configuration, concurrent with
the curing process.
[0078] Suitable substrates include, for example, heat-sensitive
substrates, such as wood, including, solid wood, wood particles,
fibers, chips, flour, pulp, and flakes; paper and cardboard;
textiles, including cotton, linen, wool, and synthetic textiles
from polyester, rayon, or nylon, and superabsorbent fibers;
vegetable fibers, such as jute, sisal, flax, cotton and animal
fibers; as well as heat resistant substrates, such as metal;
plastic; fibers, such as glass and mineral fibers, aramid fibers,
ceramic fibers, metal fibers, carbon fibers, polyimide fibers, and
woven and non-woven fabrics made therefrom. Heat-resistant
non-wovens may also contain fibers which are not in themselves
heat-resistant such as, for example, polyester fibers, rayon
fibers, nylon fibers, and superabsorbent fibers, in so far as or in
amounts such that they do not materially adversely affect the
performance of the substrate.
[0079] Non-woven fabrics are composed of fibers which can be
consolidated in whole or in part by mechanical means such as, for
example, by entanglement caused by needle-punching, by an air-laid
process, and by a wet-laid process; by chemical means such as, for
example, treatment with a polymeric binder; or by a combination of
mechanical and chemical means before, during, or after nonwoven
fabric formation. Some non-woven fabrics are used at temperatures
higher than ambient temperature such as, for example, glass
fiber-containing non-woven fabrics which are impregnated with a hot
asphaltic composition pursuant to making roofing shingles or roll
roofing material. When a non-woven fabric is contacted with a hot
asphaltic composition at temperatures of from 150.degree. C. to
250.degree. C., the non-woven fabric can sag, shrink, or otherwise
become distorted. Therefore, non-woven fabrics which incorporate a
curable composition should substantially retain the properties
contributed by the cured aqueous composition such as, for example,
tensile strength. In addition, the cured composition should not
substantially detract from essential non-woven fabric
characteristics, as would be the case, for example, if the cured
composition were too rigid or brittle or became sticky under
processing conditions.
EXAMPLES
[0080] These examples serve to illustrate the invention, outlining
specific binder compositions of this invention and ones that
compare to such compositions. The scope of the invention is not
intended to be limited by these examples.
[0081] The preparations and test procedures are carried out at room
temperature and standard pressure unless otherwise indicated.
Reagents:
[0082] Dextrose monohydrate, CAS# 5996-10-1 (Dex) Citric acid, CAS#
77-92-9 (CA) Ammonium hydroxide 28-30%, CAS# 1336-21-6,
NH.sub.3.H.sub.2O Zinc sulfate heptahydrate, CAS# 7446-20-0,
ZnSO.sub.4.7H.sub.2O
Example 1
Synthesis of Emulsion Polymers
Synthesis of Emulsion Copolymer A
[0083] After heating 340 g deionized water water and 5.0 g sodium
lauryl sulfate (28% Solids) to 90.degree. C., 2.4% of a monomer
mixture of 199 g water, 7.5 g sodium lauryl sulfate (28%), 349 g
methyl methacrylate, 100 g butyl acrylate, 2.28 g allyl
methacrylate and 4.55 g acrylamide is added followed by 5.2 g
ammonium persulfate solution (27.3% solids). This combination is
held at 88.degree. C. for 5 minutes. Then, the remaining monomer
mix is added gradually along with 19.7 g of a 1.6% aqueous ammonium
persulfate solution. The reaction mixture is cooled to 70.degree.
C. and 2.0 g of an iron sulfate solution (0.26% solids) is added.
While at 70.degree. C., 13 g of a 13.4% aqueous t-butyl
hydroperoxide solution and 26 g of a 3.8% aqueous solution of
hydroxymethane sulfonic acid monosodium salt are gradually added,
and then the mixture is further cooled to 40.degree. C. and aqueous
ammonia is added to adjust pH to 8.5. The product is filtered
through 100 and 325 mesh screens.
Synthesis of Emulsion Copolymers B and C
[0084] A 5-liter round-bottom flask equipped with a paddle stirrer,
thermocouple, nitrogen inlet, and reflux condenser was charged with
876.4 grams of deionized water, 24.2 grams of sodium hypophosphite
monohydrate, 28.5 grams of a sodium lauryl ether sulfate surfactant
solution (30%), 3.1 grams of sodium hydroxide, and 0.058 grams of
an inhibitor. The mixture was heated to 88.degree. C.
[0085] For the synthesis of polymer B, a monomer emulsion was
prepared using 459.7 grams of deionized water, 89.2 grams of a
sodium lauryl ether sulfate surfactant solution (30%), 553.9 grams
of butyl acrylate, 969.7 grams of styrene, and 268.9 grams of
acrylic acid. A 97.0 gram aliquot of this monomer emulsion was
added to the reaction flask, with stirring, followed by a solution
of 7.4 grams of ammonium persulfate dissolved in 33.3 grams of
deionized water. After an exotherm and while maintaining a reaction
temperature of 85.degree. C., the monomer emulsion and a separate
solution of 7.4 grams of ammonium persulfate in 156.9 grams of
deionized water were gradually added over a total time of 130
minutes. After these additions were complete a solution of 42.6
grams of sodium hydroxide dissolved in 397.4 grams deionized water
was added. A solution of 0.022 grams of ferrous sulfate
heptahydrate in 4.8 grams deionized water and a solution of 0.022
grams of ethylene diamine tetraacetate, tetra sodium salt,
dissolved in 4.8 grams of deionized water was added to the reaction
mixture. A solution of 7.9 grams of aqueous tert-butylhydroperoxide
(70%) diluted with 31.2 grams deionized water and a solution of 5.3
grams of sodium bisulfite dissolved in 62.8 grams of deionized
water were gradually added to the reaction mixture. After a 15
minute hold, a solution of 7.9 grams of aqueous
tert-butylhydroperoxide (70%) diluted with 31.2 grams deionized
water and a solution of 5.3 grams of sodium bisulfite dissolved in
62.8 grams of deionized water were gradually added to the reaction
mixture. After a 15 minute hold, 47.6 grams of deionized water was
added, and the reaction mixture was cooled to room temperature.
When the reaction mixture was cool below 40.degree. C., a biocide
was added and the latex was filtered through a 100 mesh sieve.
[0086] Emulsion polymer C followed this same procedure, but with
the monomer emulsion prepared as shown in Table 1. The resulting
latexes had a solids content of roughly 46.0%. The emulsion
copolymers B and C had Tg as shown in Table 1.
TABLE-US-00001 TABLE 1 Monomer Emulsion Recipes for Emulsion
Polymers B and C (weights in grams), and Copolymer Tg Emulsion
Emulsion Polymer B Polymer C Deionized water 459.7 456.8 Sodium
lauryl ether sulfate 89.2 88.7 surfactant (30%) Butyl acrylate
553.9 1072.3 Styrene 969.7 637.6 Acrylic acid 268.9 53.4 Allyl
methacrylate 0.0 17.8 Copolymer Tg (.degree. C.) 55 10
[0087] Amino resins, such as urea formaldehyde (UF) resins, are
well known and widely commercially available. They are formed, for
example, from the reaction of urea and formaldehyde to form
compounds containing methylol groups, which subsequently under the
application of heat, with or without catalysts, react further, or
condense, or cure to form polymers. The methylol groups in the
resin are known to react with active hydrogen groups such as other
methylol groups to form ether or methylene groups thereby forming
polymeric structures. Rhoplex.TM. GL-618 and Rhoplex.TM. HA-8 (both
from Rohm and Haas Company, Philadelphia, USA) are commercially
available acrylic emulsion polymers that contain methylolacrylamide
to provide sites for crosslinking to such amino resin binders.
Example 2
Preparation of Treated Glass Microfiber Filter Paper and Testing
Thereof
[0088] Aqueous curable formulations were prepared as shown in Table
2. Glass microfiber filter paper sheets (20.3.times.25.4 cm, Cat
No. 1820 866, Whatman International Ltd., Maidstone, England) were
weighed, dip-coated by hand through a trough, placed between two
pieces of cardboard, and run through a roll padder at a speed and
pressure such that the add-on was approximately 15 weight % binder.
The add-on of the coated sheets was determined as the cured binder
weight as a percentage of filter paper weight. Each sheet was dried
in a Mathis oven set to 90.degree. C. for 90 seconds and cured in
another Mathis oven at specified times and temperature.
[0089] The cured sheets were cut into fourteen 1 inch (cross
machine direction) by 4 inch (machine direction) strips and tested
for tensile strength in the machine direction in a Thwing-Albert
EJA Vantage Universal tensile tester. The fixture gap was 2 inches
and the pull rate was 2 inches/minute and the sensitivity was 10
lb. Both the dry and hot-wet tensile data reported is the average
peak force measured during testing of seven test strips. For
hot-wet tensile strength testing, strips were tested immediately
after a 30 minute soak in water at 85.degree. C.
Example 3
Early Strength Development of Saccharide Binders: Effect of Lewis
Acid
[0090] For each sample, comparative examples Comp. A1-A2 and
inventive example Ex. A1, the formulation components were simply
admixed in aqueous solution using a benchtop stirrer.
[0091] The binder was applied and cured on glass microfiber filter
paper sheets as described in Example 2 (above), and then tested for
hot wet tensile properties (Table 2, below). The binder add-on was
approximately 15%. Binders based on sugars often have acceptable
dry tensile strength properties, however, the soluble nature of the
sugars invariably compromises the hot wet tensile properties of
these systems, which properties are considered important.
[0092] Aqueous compositions comprising a carbohydrate and an
ammonium salt of a polycarboxylic acid have recently been proposed
as thermosetting or curable binders. However, such systems have
been found to be lacking with respect to early cure and strength
development. Table 2, below, presents the formulation components,
in grams, for some representative aqueous binder compositions of
the invention and shows the effect of a Lewis acid in such
systems.
TABLE-US-00002 TABLE 2 Formulation Components and Hot Wet Tensile
(lb.) after curing at 190.degree. C..sup.1 Lewis Hot Wet Hot Wet
Acid (g.) Tensile (lbf) Tensile (lbf) Sample Dex (g.) CA (g.)
NH.sub.3.cndot.H.sub.20 (g.) (ZnSO.sub.4) (30 sec. cure) (60 sec.
cure) Comp. A1 20.00 -- -- -- 0 0 Comp. A2 15.00 2.73 2.42 -- 0 1.5
Ex. A1 15.00 2.73 2.42 3.15 2.0 5.2 .sup.1On glass
microfilterpaper; binder add-on is approximately 15%.
[0093] The data in Table 2 shows that the addition of a Lewis acid,
zinc sulfate, accelerates and greatly enhances the early cure and
strength development of aqueous curable binder compositions
comprising a carbohydrate and an ammonium salt of a polycarboxylic
acid (as shown, for example, by comparison of Ex. A1 and Comp.
A2).
Example 4
Mechanical Properties of Binder Compositions on Glass Mat
Glass Mat Preparation Procedure
[0094] To prepare the glass mats used in the samples in Table 2,
glass fiber non-woven handsheets are prepared with Johns Manville
137 Standard, 3.2 cm (11/4 inch) length, sized glass chop using
approximately 7.6 grams of glass fiber per sheet (0.82 kg per 9.3
square meters; 1.8 pounds per 100 square feet). The glass fiber is
dispersed in water using SUPERFLOC.TM. A-1883 RS (Cytec Industries
Incorporated, West Paterson, N.J., USA), an anionic polyacrylamide
water-in-oil emulsion, and RHODAMEEN.TM. VP-532 SPB (Rhodia
Chemical Company, Cranbury, N.J., USA), an ethoxylated fatty amine
cationic dispersing agent. Handsheets are formed in a Williams
(Williams Apparatus Company, Watertown, N.Y., USA) handsheet mold.
The wet sheets are transferred to a vacuum station and de-watered.
In each case, the aqueous binder composition is applied to a
de-watered sheet and the excess is vacuumed off. The sheets are
dried/cured in a forced air oven for 21/2 minutes at 200.degree. C.
The binder amount on the samples is 17% LOI (loss on ignition).
Determination of LOI (Loss On Ignition)
[0095] A 6.4 cm by 7.6 cm (2.5 inch by 3 inch) piece of dried/cured
fiberglass mat was cut. The sample was weighed and then placed in a
muffle furnace at 650.degree. C. for 2 minutes.
[0096] The sample was removed and then reweighed. % LOI was
calculated using the equation: % LOI=(wt. before burning-wt. after
burning).times.100/(wt. before burning).
Room Temperature Testing of Tensile Strength and Elongation
[0097] An Instron 4201 tensile tester equipped with a 1 kN load
cell and an oven chamber encasing the jaws with temperature range
of -100 to 400.degree. F. (-73.degree. C. to 204.degree. C.)
capability was used for room temperature (RT) tensile strength,
hot-wet tensile strength, high temperature (hot-dry) tensile
strength, and room temperature elongation.
[0098] For RT tensile strength and RT elongation, a cured sheet was
cut into 11/2''.times.10'' strips. Strips were tested by placing
them in the jaws of the tensile tester and pulled apart at a
crosshead speed of 8 inches/minute with a 6'' gap. The maximum RT
tensile strength is measured, and expressed in pounds force (lbf).
Elongation (strain) is measured at maximum RT tensile strength, and
expressed as %. Both the dry and hot-wet tensile data reported is
the average peak force measured during testing of seven test strips
and expressed in pounds force (lbf). Strips were tested either "as
is" (dry tensile) or immediately after a 30 minute soak in water at
85.degree. C.
Hot-Dry Tensile Strength
[0099] A cured sheet is cut into 2''.times.12'' strips. The oven
chamber of the tensile tester is pre-heated to 375.degree. F.
(190.degree. C.) prior to testing. Once pre-heated, the strips are
placed in the jaws and the oven chamber closed and equilibrated
back to 375.degree. F. The samples are then pulled apart at a
crosshead speed of 8 inches/minute with a 8'' gap. Hot Tensile
Strength is measured at 20% elongation (strain), and expressed in
pounds force (lbf).
Elmendorf Tear Strength Testing
[0100] Elmendorf tear strength is determined on cut samples of
dried/cured handsheet which are 6.4 cm by 7.6 cm (2.5 inches by 3
inches). A single ply sample is placed in a Thwing-Albert Tear
Tester with a 1600 g tear arm. The sample is notched with a 1.9 cm
(0.75 inch) cut and the arm is released. The tear strength is
recorded in grams (grams force).
Polymer Modified Saccharide Binder Compositions
[0101] The formulations for the samples presented in Table 3 were
prepared as described earlier; Comp. C2 uses the addition of 175.0
grams, g., (159.1 g. dry weight) dextrose, 381.6 g. water, 28.9 g.
citric acid, and 25.5 g. (7.7 g. dry weight) ammonium hydroxide.
For the polymer modified binder compositions, a latex emulsion
polymer was added, with stirring in an amount equal to 10% or 20%
by weight of polymer solids based on the weight of total solids of
the other components in the composition. The binder was applied and
cured on glass mats and then tested for mechanical properties
(Tables 3, below). The binder add-on was approximately 17% on the
glass mats.
TABLE-US-00003 TABLE 3 Mechanical properties of saccharide
thermoset compositions comprising an emulsion polymer.sup.1 Room
Temp. Hot-Wet Hot-Dry Tensile Strength Tensile Strength Tensile
Strength Tear Strength ID Formulation (lbf) (lbf) (lbf) (grams-f)
C1 UF Resin.sup.2 32.9 21.2 35.5 498 C2 Dex + (NH.sub.4)Citrate
30.7 19.1 24.8 333 C3 Dex + 20% Polymer A 8.4 0.0 8.7 724 C4 Dex +
20% Polymer B 5.5 0.0 0.2 614 Ex. 1 Dex + (NH.sub.4)Citrate + 37.3
19.3 30.1 789 10% Polymer A Ex. 2 Dex + (NH.sub.4)Citrate + 44.3
25.3 24.1 666 20% Polymer A Ex. 3 Dex + (NH.sub.4)Citrate + 24.9
24.5 22.5 710 20% Polymer B .sup.1On glass mat; binder add-on
approximately 17%. .sup.2The UF resin is SU-100, from Hexion
Specialty Chemicals, Columbus, Ohio, USA (a commercial
urea-formaldehyde binder for this application).
[0102] The data in Table 3 show that addition of 10% or 20%
emulsion polymer can favorably impact the balance of properties in
these saccharide binder systems, although in some cases there may
be a trade-off in performance attributes.
Example 5
Mechanical Properties of Binder Compositions on Spunbond
Polyester
Polyester Spunbond Mat Preparation:
[0103] More flexible systems are tested on polyester spunbond mat.
Commercial polyester spunbond mat (non-treated) is cut into
15''.times.12'' sheets. Sheets are dip coated in test binder
formulation at 11% bath solids (by weight). Soaked sheets are
padded at 40 psi and then immediately cured at 200.degree. C. for 3
minutes. Binder add-on is about 20% by weight.
Room Temperature Testing: Tensile Strength, Elongation for
Polyester Spunbond Mat
[0104] Room temperature testing of tensile strength and elongation
for polyester spunbond mat was performed in the same manner as
described above for glass mat.
TABLE-US-00004 TABLE 4 Effect of addition of emulsion polymer on
saccharide thermoset properties.sup.1 Dextrose +
(NH.sub.4)Citrate.sup.3 RT Tensile Elongation Sample Latex
Modifier.sup.2 (lbf) (%) Comp. B1 None 80.5 40 Ex. B1 Polymer C
84.7 43 Ex. B2 GL-618 86.2 42 Ex. B3 HA-8 90.2 54 .sup.1On spunbond
polyester mat (flexible substrate); binder add-on is approximately
20%. .sup.2Latex modifier is added at a level of 10% by weight of
solids as a percentage of total solids of other binder components.
.sup.3Formulation ratios are as described for the samples in Table
3.
[0105] The data in Table 4 show that addition of 10% emulsion
polymer (polymer solids as a percentage of other composition
component solids) can show improvement in both room temperature
tensile strength and % elongation properties. These inventive
compositions thus provide an inexpensive, formaldehyde-free,
thermoset binder that retains both flexibility and strength after
cure. The inventive compositions derive primarily from renewable
resources as opposed to petroleum feedstocks.
* * * * *